Terex Genie Z331815M-101 User manual

1.
Operator's Manual
Z-33/18
DC Power
Original Instructions
First Edition
Second Printing
Part No. 1257144GT
with
Maintenance
Information
ANSI/CSA
North America
South America
Asia
Serial number range
From Z331815M-101
to Z331816M- 1299
From Z3318M-1300

II Z-33/18 Part No. 1257144GT
First Edition • Second Printing
Operator's Manual
Contents
Introduction.......................................................... 1
Symbol and Hazard Pictorials Definitions............ 5
General Safety..................................................... 7
Personal Safety ................................................. 11
Work Area Safety .............................................. 12
Legend............................................................... 19
Controls ............................................................. 20
Inspections ........................................................ 25
Operating Instructions ....................................... 37
Transport and Lifting Instuctions ....................... 43
Maintenance...................................................... 46
Specifications .................................................... 48
Copyright © 2018 by Terex Corporation
First Edition: Second Printing, August 2018
Genie and "Z" are registered trademarks of Terex South
Dakota, Inc. in the U.S.A. and many other countries.
These machines comply with
ANSI/SIA 92.5
CAN B.354.4
TEREX Global GmbH
Bleicheplatz 2
8200 Schaffhausen
Switzerland
Technical Assistance Service
Telephone: [phone]
[phone]
e-mail: [email protected]

Part No. 1257144GT Z-33/18 1
First Edition • Second Printing Operator's Manual
Introduction
About this manual
Genie appreciates your choice of our machine for
your application. Our number one priority is user
safety, which is best achieved by our joint efforts.
This book is an operation and daily maintenance
manual for the user or operator of a Genie
machine.
This manual should be considered a permanent
part of your machine and should remain with the
machine at all times. If you have any questions,
contact Genie.
Product Identication
The machine serial number is located on the serial
label.
Intended Use
This machine is intended to be used only to lift
personnel, along with their tools and materials to
an aerial work site.
Bulletin Distribution and
Compliance
Safety of product users is of paramount
importance to Genie. Various bulletins are used
by Genie to communicate important safety and
product information to dealers and machine
owners.
The information contained in the bulletins is tied to
specific machines using the machine model and
serial number.
Distribution of bulletins is based on the most
current owner on record along with their
associated dealer, so it is important to register
your machine and keep your contact information
up to date.
To ensure safety of personnel and the reliable
continued operation of your machine, be sure to
comply with the action indicated in a respective
bulletin.
CG
Sequence number
stamped on chassis
Serial label
(located under cover)

2 Z-33/18 Part No. 1257144GT
First Edition • Second Printing
Operator's Manual
Introduction
Contacting the Manufacturer
At times it may be necessary to contact Genie.
When you do, be ready to supply the model
number and serial number of your machine,
along with your name and contact information. At
minimum, Genie should be contacted for:
Accident reporting
Questions regarding product applications and
safety
Standards and regulatory compliance information
Current owner updates, such as changes in
machine ownership or changes in your contact
information. See Transfer of Ownership, below.
Transfer of Machine Ownership
Taking a few minutes to update owner information
will ensure that you receive important safety,
maintenance and operating information that
applies to your machine.
Please register your machine by visiting us on the
web at www.genielift.com.

Part No. 1257144GT Z-33/18 3
First Edition • Second Printing Operator's Manual
Introduction
Danger
Failure to obey the instructions and
safety rules in this manual will result
in death or serious injury.
Do Not Operate Unless:
You learn and practice the principles of safe
machine operation contained in this operator’s
manual.
1 Avoid hazardous situations.
Know and understand the safety rules before
going on to the next section.
2 Always perform a pre-operation inspection.
3 Always perform function tests prior to use.
4 Inspect the workplace.
5 Only use the machine as it was intended.
You read, understand and obey the
manufacturer’s instructions and safety
rules–safety and operator’s manuals and
machine decals.
You read, understand and obey employer’s
safety rules and work site regulations.
You read, understand and obey all applicable
governmental regulations.
You are properly trained to safely operate the
machine.

4 Z-33/18 Part No. 1257144GT
First Edition • Second Printing
Operator's Manual
Introduction
Safety Sign Maintenance
Replace any missing or damaged safety signs.
Keep operator safety in mind at all times. Use
mild soap and water to clean safety signs. Do not
use solvent-based cleaners because they may
damage the safety sign material.
Hazard Classication
Decals on this machine use symbols, color coding
and signal words to identify the following:
Safety alert symbol—used to
alert personnel to potential
personal injury hazards. Obey
all safety messages that follow
this symbol to avoid possible
injury or death.
DANGER
Indicates an imminently
hazardous situation which, if
not avoided, will result in death
or serious injury.
WARNING
Indicates a hazardous situation
which, if not avoided, could
result in death or serious injury.
CAUTION
Indicates a hazardous situation
which, if not avoided, may
cause minor or moderate injury.
NOTICE
Indicates a property damage
message.

Part No. 1257144GT Z-33/18 5
First Edition • Second Printing Operator's Manual
Symbol and Hazard Pictorials Denitions
12.5 m/sec
12.5 m/sec
12.5 m/sec
12.5 m/sec
Crush hazard Explosion hazard Collision hazard Collision hazard Runaway Hazard
12.5 m/sec
12.5 m/sec
12.5 m/sec
12.5 m/sec
12.5 m/sec
Tip-over hazard Tip-over hazard Raise platform on
firm, level surface
Electrocution
hazard
Maintain required
clearance
12.5 m/sec
12.5 m/sec
12.5 m/se
c
12.5 m/sec
12.5 m/sec
Color Coded
Direction Arrows
Maximum capacity Wind speed Manual force Only trained
maintenance
personnel
should access
compartments
Electrocution
hazard
Grounded AC
3-wire outlet only
Replace damaged
wires and cords
Batteries used as
counterweight
Burn hazard

6 Z-33/18 Part No. 1257144GT
First Edition • Second Printing
Operator's Manual
Symbol and Hazard Pictorials Denitions
Recovery procedure if tilt alarm sounds
while elevated.
No smoking
No flame
Stop engine
Read the
operator’s
manual
Platform uphill:
1 Lower primary
2 Lower secondary
3 Retract primary
Platform downhill:
1 Retract primary
2 Lower secondary
3 Lower primary
Wheel load
No smoking
Lanyard anchorage
point
Replace tires with
tires of same
specification.
Voltage rating for
power to platform
Pressure rating for
air line to platform

Part No. 1257144GT Z-33/18 7
First Edition • Second Printing Operator's Manual
General Safety
Safety Signs and Locations
1261933
31060
31508
31508
1261933
31060 114390 3178731788
1261933
31060
Tip-over Hazard
Altering or disabling limit
switches can result in machine
tip-over. Machine tip-over will
result in death or serious injury.
Do not alter or disable limit
switch(s).
31060 C
DANGER
Explosion/Burn Hazard
Battery explosion and/or contact with
corrosive acid will result in death or serious
injury.
Wear appropriate personal protective
equipment, including gloves, face shield
and long sleeve shirt.
Read manuals. If you do not understand
the information in the manuals, consult your
supervisor, the owner or the manufacturer.
Keep all open flames
and sparks away.
31788 D
114390
31788
31787
1261933 B
Solid Rubber NM Tires
Tire size: 22x9x17
Tire Contact Pressure
70 psi / 483 kPa
Wheel Lug Torque
Dry: 125 ft-lbs / 169 Nm
Lubricated: 94 ft-lbs /
127 Nm
Tip-over Hazard
Tipping over this
machine will
result in death or
serious injury.
Do not replace
factory installed
tires with tires of
a different
specification or
ply rating
DANGER
31787 G
Tip-over Hazard
Tipping over this machine
will result in death or
serious injury.
Minimum battery weight:
Minimum battery box weight:
≥ 105 lbs / 47.6 kg
≥ 530 lbs / 240.4 kg

8 Z-33/18 Part No. 1257144GT
First Edition • Second Printing
Operator's Manual
General Safety
Safety Signs and Locations
1261934
218559
28236
218559
1261933
31788
31787
31060 114390
114397
1262132
1261934
1261933
28236
1262132
114390
1261934 A
Tip-over Hazard
Tipping over the machine will result
in death or serious injury.
Maximum
allowable wind
speed:
28 mph /
12.5 m/sec
Maximum
Allowable
Manual Force:
150 ft lbs / 667 N
Maximum Capacity:
441 lbs / 200 kg
Occupants and
equipment must not
exceed
441 lbs / 200 kg
Maximum
Occupants: 2
218559 A
Keep away from overhead obstructions
or other possible hazards.
Crush Hazard
Contact with overhead obstructions
could result in death or serious injury.
Drive Direction Hazard
Machine can move in opposite direction of
joystick movement. Movement in an unplanned
direction can result in death or serious injury.
Always match the color-coded direction arrows
on platform controls and drive chassis to
determine direction of machine travel. Read
and understand operator's manual.
Only raise the platform when the
machine is on a firm, level surface.
Tip-over Hazard
Tipping over this machine will
result in death or serious injury.
Runaway Hazard
Machine movement can occur
when machine is operated on
a slope that exceeds rated
uphill, downhill or side slope
rating. A runaway machine
could result in death or
serious injury.
Driving on a Slope
Do not drive machine on a slope
that exceeds maximum uphill,
downhill or side slope rating.
Determine slope and side slope ratings for
and determine slope grade.
Maximum slope rating, platform
downhill (gradeability) 30% (17°)
Maximum slope rating,
platform uphill 20% (11°)
Maximum side slope rating 25% (14°)
Note: Slope rating is subject to ground
conditions and adequate traction. Gradeability
applies to platform downhill configuration only.
Be sure boom is below horizontal
and platform is between non-steer
wheels.
Move drive speed select switch to
machine on incline symbol.
1262132 A
WARNING
3
3
5285
119
5285
128819
128819
52865
52865 114397
1280819
1280819

Part No. 1257144GT Z-33/18 9
First Edition • Second Printing Operator's Manual
General Safety
Safety Signs and Locations
114249
114252 133067
114334
114345
114334
114249
114252 133067 11434582481
114249
114252
82481
82481 D

10 Z-33/18 Part No. 1257144GT
First Edition • Second Printing
Operator's Manual
General Safety
Safety Signs and Locations
114249
114248
400 N
1258501 A
200 kg
< =
200 kg
+
12.5 m/sec
1258501
219958 A
219958
82487
219958
114249
82481
114345
114252133067 82487
133067
219956
1258501
114248
114249
82487
82487 D
219956 A
219956
1261869 A
30% (17°)
20% (11°)
25% (14°)
1261869
1261869

Part No. 1257144GT Z-33/18 11
First Edition • Second Printing Operator's Manual
Personal Safety
Personal Fall Protection
Personal fall protection equipment (PFPE) is
required when operating this machine.
Occupants must wear a safety belt or harness in
accordance with governmental regulations. Attach
the lanyard to the anchor provided in the platform.
Operators must comply with employer, job site and
governmental rules regarding the use of personal
protective equipment.
All PFPE must comply with applicable
governmental regulations, and must be
inspected and used in accordance with the PFPE
manufacturer’s instructions.

12 Z-33/18 Part No. 1257144GT
First Edition • Second Printing
Operator's Manual
Work Area Safety
Electrocution Hazards
This machine is not electrically insulated and will not
provide protection from contact with or proximity to
electrical current.
ì Obey all local and
governmental regulations
regarding required
clearance from electrical
power lines. At a minimum,
the required clearance
contained in the chart
below must be followed.
Line Voltage Required Clearance
0 to 50KV 10 ft 3.05 m
50 to 200KV 15 ft 4.60 m
200 to 350KV 20 ft 6.10 m
350 to 500KV 25 ft 7.62 m
500 to 750KV 35 ft 10.67 m
750 to 1000KV 45 ft 13.72 m
Allow for platform movement, electrical line sway
or sag, and beware of strong or gusty winds.
Keep away from the
machine if it contacts
energized power lines.
Personnel on the ground
or in the platform must not
touch or operate the
machine until energized
power lines are shut off.
Do not operate the machine during lightning or
storms.
Do not use the machine as a ground for welding.
Tip-over Hazards
Occupants, equipment and materials shall not
exceed the maximum platform capacity or the
maximum platform capacity of the platform
extension.
Maximum platform capacity 440 lbs /
200 kg
Maximum occupants 2
The weight of options and accessories, such
as pipe cradles, panel cradles and welders, will
reduce the rated platform capacity and must be
subtracted from the platform capacity. See the
decals with the options and accessories.
If using accessories, read, understand and obey
the decals, instructions and manuals with the
accessory.
Do not alter or disable the limit switches.
Do not raise or extend the boom unless the
machine is on a firm, level surface.
Do not depend on the tilt alarm as a level indicator.
The tilt alarm sounds in the platform only when the
machine is on a severe slope.

Part No. 1257144GT Z-33/18 13
First Edition • Second Printing Operator's Manual
Work Area Safety
If the tilt alarm sounds while the boom is lowered:
do not extend, rotate or raise the boom above
horizontal. Move the machine to a firm, level
surface before raising the platform.
If the tilt alarm sounds when the platform is raised,
use extreme caution. The Machine Not Level
indicator light will come on and the drive function
in one or both directions will not operate. Identify
the condition of the boom on the slope as shown
below. Follow the steps to lower the boom before
moving to a firm, level surface. Do not rotate the
boom while lowering.
If the tilt alarm sounds with
the platform uphill:
1 Lower the primary
boom.
2 Lower the secondary
boom.
3 Retract the primary
boom.
If the tilt alarm sounds with
the platform downhill:
1 Retract the primary
boom.
2 Lower the secondary
boom.
3 Lower the primary
boom.
-
Do not raise the boom when
wind speeds may exceed
12.5 m/s. If wind speeds
exceed 12.5 m/s when the
boom is raised, lower the
boom and do not continue to
operate the machine.
Do not operate the machine in strong or gusty
winds. Do not increase the surface area of the
platform or the load. Increasing the area exposed
to the wind will decrease machine stability.
Use extreme care and
slow speeds while driving
the machine in the stowed
position across uneven
terrain, debris, unstable or
slippery surfaces and near
holes and drop-offs.
Do not drive the machine on or near uneven
terrain, unstable surfaces or other hazardous
conditions with the boom raised or extended.
Do not use the machine as a crane.
Do not push the machine or other objects with the
boom.
Do not contact adjacent structures with the boom.

14 Z-33/18 Part No. 1257144GT
First Edition • Second Printing
Operator's Manual
Work Area Safety
Do not tie the boom or platform to adjacent
structures.
Do not place loads outside the platform perimeter.
Do not push off or pull
toward any object outside of
the platform.
Maximum allowable
manual force
150 lbs / 667 N
Do not alter or disable machine components that
in any way affect safety and stability.
Do not replace items critical to machine stability
with items of different weight or specification.
Do not replace factory-installed tires with tires of
different specification or ply rating.
Do not use air-filled tires. These machines are
equipped with solid tires.
Wheel weight and proper counterweight
configuration are critical to stability.
Do not modify or alter an aerial work platform
without prior written permission from the
manufacturer. Mounting attachments for holding
tools or other materials onto the platform,
toeboards or guard rail system can increase the
weight in the platform and the surface area of the
platform or the load.
Do not place or attach
fixed or overhanging
loads to any part of this
machine.
Do not place ladders or
scaffolds in the platform
or against any part of this
machine.
Do not transport tools and materials unless they
are evenly distributed and can be safely handled
by person(s) in the platform.
Do not use the machine on a moving or mobile
surface or vehicle.
Be sure all tires are in good condition and lug nuts
are properly tightened.
Do not use the platform controls to free a platform
that is caught, snagged or otherwise prevented
from normal motion by an adjacent structure. All
personnel must be removed from the platform
before attempting to free the platform using the
ground controls.
Do not use batteries that weigh less than the
original equipment. Batteries are used as
counterweight and are critical to machine stability.
Each battery must weigh a minimum of 105 lbs /
47.6 kg. Each battery box including batteries must
weigh a minimum of 530 lbs / 240.4 kg.

Part No. 1257144GT Z-33/18 15
First Edition • Second Printing Operator's Manual
Work Area Safety
Operation on Slopes Hazards
Do not drive the machine on a slope that exceeds
the maximum uphill, downhill or side slope rating
of the machine. Slope rating applies only to
machines in the stowed position.
Maximum slope rating, stowed position
Platform downhill 30% (17°)
Platform uphill 20% (11°)
Side slope 25% (14°)
Note: Slope rating is subject to ground conditions
and adequate traction. See Driving on a Slope in
the Operating Instructions section.
Fall Hazards
Occupants must wear a
safety belt or harness in
accordance with
governmental regulations.
Attach the lanyard to the
anchor provided in the
platform.
Do not sit, stand or climb
on the platform guard
rails. Maintain a firm
footing on the platform
floor at all times.
Do not climb down from
the platform when raised.
Keep the platform floor clear of debris.
Lower the platform entry mid-rail or close the entry
gate before operating.
Do not enter or exit the platform unless the
machine is in the stowed position and the platform
is at ground level.
Collision Hazards
Be aware of limited sight
distance and blind spots
when driving or operating.
Be aware of the boom position and tailswing when
rotating the turntable.
Check the work area for
overhead obstructions or
other possible hazards.

16 Z-33/18 Part No. 1257144GT
First Edition • Second Printing
Operator's Manual
Work Area Safety
Be aware of crushing
hazards when grasping the
platform guard rail.
Operators must comply with employer, job site
and governmental rules regarding use of personal
protective equipment.
Observe and use the color-coded direction arrows
on the platform controls and drive chassis for drive
and steer functions.
Do not lower the boom
unless the area below is
clear of personnel and
obstructions.
Limit travel speed
according to the condition
of the ground surface,
congestion, slope, location
of personnel, and any other
factors which may cause
collision.
Do not operate a boom in the path of any crane
unless the controls of the crane have been locked
out and/or precautions have been taken to prevent
any potential collision.
No stunt driving or horseplay while operating a
machine.
Bodily Injury Hazard
Do not operate the machine with a hydraulic oil or
air leak. An air leak or hydraulic leak can penetrate
and/or burn skin.
Improper contact with components under
any cover will cause serious injury. Only
trained maintenance personnel should access
compartments. Access by the operator is only
advised when performing a pre-operation
inspection. All compartments must remain closed
and secured during operation.
Explosion and Fire Hazards
Charge the batteries only in an open, well-
ventilated area away from sparks, flames and
lighted tobacco.
Do not operate the machine or charge the
batteries in hazardous locations or locations
where potentially flammable or explosive gases or
particles may be present.

Part No. 1257144GT Z-33/18 17
First Edition • Second Printing Operator's Manual
Work Area Safety
Damaged Machine Hazards
Do not use a damaged or malfunctioning machine.
Conduct a thorough pre-operation inspection of
the machine and test all functions before each
work shift. Immediately tag and remove from
service a damaged or malfunctioning machine.
Be sure all maintenance has been performed as
specified in this manual and the appropriate Genie
service manual.
Be sure all decals are in place and legible.
Be sure the operator’s, safety and responsibilities
manuals are complete, legible and in the storage
container located on the platform.
Component Damage Hazards
Do not use the machine as a ground for welding.
When the boom is not completely retracted, some
machine components may collide with the ground
or the chassis. Be careful while the platform is
approaching to the ground.
Lockout After Each Use
1 Select a safe parking location–firm level surface,
clear of obstruction and traffic.
2 Retract and lower the boom to the stowed
position.
3 Rotate the turntable so that the boom is
between the non-steer wheels.
4 Turn the key switch to the off position and
remove the key to secure from unauthorized
use.

18 Z-33/18 Part No. 1257144GT
First Edition • Second Printing
Operator's Manual
Work Area Safety
Battery Safety
Burn Hazards
Batteries contain acid
Always wear protective
clothing and eye wear when
working with batteries.
Avoid spilling or contacting
battery acid. Neutralize
battery acid spills with
baking soda and water.
The battery pack must remain in the upright
position.
Do not expose the batteries or the charger to
water or rain.
Explosion Hazards
Keep sparks, flames and
lighted tobacco away from
batteries. Batteries emit an
explosive gas.
The battery pack cover must
remain off during the entire
charging cycle.
Do not contact the battery
terminals or the cable clamps
with tools that may cause
sparks.
Component Damage Hazards
Do not use any battery charger greater than 48V
to charge the batteries.
Both battery packs must be charged together.
Disconnect the battery pack plug before removing
the battery pack.
Electrocution Hazards
Connect the battery charger
to a grounded, AC 3-wire
electrical outlet only.
Inspect daily for damaged
cord, cables and wires.
Replace damaged items before
operating.
Avoid electrical shock from
contact with battery terminals.
Remove all rings, watches and
other jewelry.
Tip-over Hazards
Do not use batteries that weigh less than the
original equipment. Batteries are used as
counterweight and are critical to machine stability.
Each battery must weigh a minimum of 105 lbs /
47.6 kg. Each battery box including batteries must
weigh a minimum of 530 lbs / 240.4 kg.
Lifting Hazards
Use a forklift to remove or install the battery packs.